Manufacture of composite metallic structures



Apri] 18, 1939- R. M. KENAH 2,155,274

` MANUFECTURE OF CQMFOSITE METALLIG STRUCTURES Filed Dec. 2 1, 1934 2 Sheets-Sheet 1 4 VI llllllllllllmm W///// m [NVENTOR 72 /CLJ ApriIlS, 1939. R; M. KENAH 2,155,274

MANUFACTURE OF COMFOSITE METALLIC STRUCTURES Filed Dec.. 21, 954 2 Sheets-Sheet 2 SOLDER.

COATNG.

Patented Apr. 18, 1939 UNITED STATES MANIFACTURE OF COMPOSITE METALLIC STRUCTURES Roland M. Kenah, New Briglton, Pa., assignor to Standard Specialty & l'be Company, New Briglton, Pa., acorporation of New Jersey Application December 21, 1934, Serial No. '758,563

7 Claims. (Cl. .za- 1482 This invention relates broadly to the manufacture of composite metallic structures, and more particularly composite metallic structures made up of parts adapted to be bonded together,

as by soldering.

In certain of its n'ore specific aspects the invention relates to the` manufacture of spcuted containers, and especially containers having separate body and spout members which are bond- 10 ed together. The invention further relates to a blank or spout member adapted for use in the manufacture of containers and to the manufacture of such blank or spout member.

In the copending application of Paul E. Brunl-S berg, Serial No. '758,565, filed of even date herewith, there is disclosed and claimed a composite 'metallic structure and a method. of manufacture of such a structure entailing the use of a bonding medium such as solder to bond together the :u Component parts of the structure. In such application there is disclosd; pur'ely by way of example, the manufacture of an oil can by providing separate can body and spout members, assembling such members with solder therebetween and melting and then hardening the solder to bond the parts together. If it is attempted to apply the 'solder to one or the other of the preformed container members difficulty is encountered in obtaining a smooth uniform layer of solder without wastage of solder, and the step of thus applying the solder is an undesirable and costly one. g

I provide for the manufacture of composite metallic structures by forming a blank having solder applied thereto, shaping such blank to forma part adapted for incorporation in the composite metallic'structure with the solder disposed at a predeterminecl position thereon, assembling such part with another part withthe solder opposite a bimetallic billet which may be rolled down to plate or sheet form of predetermined thickness, and I form therefrom, as, for example, by stamping or punching, one or more blanks suitable 'for shaping into the desired container member. Preferably the hacking material is plasticmetal, such, for example, as lead, tin, antimony, aluminum. etc., either singly or in combination. The

( n blank is p'referably die-formed or extruded 'to' form the' desired member, which may, for example, be a spout member, and on which the solder will be predeterminedly positioned. such member may then be suitably assembled with a ooperating container member and with the solder opposite a'portion of the latter, whereupon the solder is melted and then hardened to bond the 'members together. By the word "melted" I mean that the solder is rendered sufliciently plastic and is'raised to a sufficient temperature totform the desired bond.

Other details, objects and advantages of the invention will become apparent as the following description of a present preferred embodiment thereof and` of a present preferred method of practicing the same proceeds. i

In ,the accompanylng drawings I have shown a present preerred embodiment of the invention, in which I Figure 1 is a cross-sectional view through a portion of a bimetallic billet;

Figure '2 is a cross-sectional view through a portion of a plate or sheet ormed from the billet shown in Figure 1;

Figure 3 is a top plan View of a blank or slug formed from the plate or sheet shown in Figure 2;

Figure 4 is a transverse cross-sectional view through the blank or slug shown in Figu'e 3 and taken on the line IV-IVof that figure;

Figure 5 is a diagrammatic vertical transverse cross-sectional view through die-forming apparatus with the slug shown in Figures '3 and 4 in place therein and prior to the die-forming operation;

Figure 6 is a view similar to Figura 5- with the plunger in its lowermost position at the completion of the die-forming operation;

Figure 7 is an elevational view, partly in central vertical cross section, of the body member and the spout member of an oil can prior to their assembly in the manufacture of a spcuted can; Figure 8 is a view similar to Figure 7 but' showing the spout member applied to the body member and also showing, .purely diagrammatically, heated crimping` dies which may be used to crimp the body and spout members together and melt the solder; and

Fi'gure 9 is a greatly enlarged partial central vertical cross-sectional view through a portion of 'the Construction shown in Figure 8.

Purely for the sake of explanation and illustration the invention will be described in coni nection with the manufacture of an oil can.

Referring now more particularly to the drawings, there is shown in Figure 1 a bimetallc billet, designated generally by reference numeral 2, which comprises a base or hacking portion 3 and a facing 4. The base or hacking portion 3 may be of any suitable material, but in the exampie' chosen will be considered as being of plastic material, such, for example, as lead, tin. antimony, aluminum, etc., either singly or in comhination. The facing 4 is of solder, prefera bly a solder of tin and lead. A solder of 63% tin and 37 lead has been found especially well suited tor my purpose when the plastic material islead' or a lead alloy. The bimetallic billet 2 `is preferably formed by assemblng the bese or hacking portion,which may be in billet form, and 'a sheet of' the !acing material or solder.

The bimetallic billet 2'is next compressed, as,

for example, by rolling in any suitable rolling mill, 'the compressing ordinarily preferably being done cold, to produce a bimetallic plate or sheet of predetermined thickn'ess shown in Fig'ure 2 and designated generally by reference numeral 5. The comp'essing not only reduces the thickness of the blmetallic member but also assists'in consolidating thefacing and hacking portlons thereof.

Blanks or slug's as shown in Figures 3 and 4 are then formed from the bimetallic plate or sheet 5, this preferably being done by blanking or' punching. For example, the blanks or slugs may be punched out of the bimetallic sheet, the punch and die being designed so that the slugs will have the sh'ape shown. Each slug comprises a body portion S and a facing the slug as a whole being dlshed concavely upwardly as shown in Figure4. The slug may be in the form of a flat disc but is preferably formed of dish shape for' a purpose now to be described. I

The slug is placed with the facing 'I upwardly: in a die 'cavity 8 formed in a die block 9. The .i

I to determlne this at a glance, as it is known that the slugs are manufactured with the concave face on the same side as the facing 1.

The plunger which cooperates with the die I .block 9 is shown at l I and has a reduced tapered 'nose I2. The plunger is of course suitably guided as well known inthe art relative to the die block and, after the slug is positioned in the die cavity 8 as shown in Figure 5, the plunger is moved downwardly into the die cavity, the nose za of the plunger striking the center of the slug and the plunger being coaxial' with the die-cavities 8 and III. The slug is shaped or die-formed into the form shown in ,Figura 6, this being a spout blank, designated generally by reference numeral I 3. such blank has anose portion ll and a skirt portion !5 and is partially internally lined with solder as shown at IS. In the die formin'g operation the nose of the plunger probably passes completely .through the solder'aclng on the slug so that the extren ity of the nose portion of the spout blank may not be internally lined with solder. However, as will presently appear, it is immaterial whether or not the nose portion of the spout blank s internally lined with solder. The blank isgso formed and the plunger and die so shaped thata lining oi' solder of substantially uniform thickness is form'ed within 'the skirtportiou li of the spout blank after the die-iorming operation, as shown in Figure 6.

' iacture.

The solder lining extendspart way toward the nose of the spout blank, probably tapering of! to zero thickness about half way between the skirt portion and the noseextremity of the blank. The lining of solder is firmly consoli- -dated with the hacking material and has a smooth exterior surface.

` The plunger is then withdrawn andthe blank I! removed from the die cavity. Normally the blank adheres to the plunger and when the plunger is withdrawn the blank is withdrawn with itand the blank is thereafter removed from the plunger. The blank isthen trimmed and its. 'nose threaded as shown at ll in Figures 7, 8 and 9, after which a cap is screwed on.. thus forming a spout member which is finished except for application to the container. All of the Operations in the formation of the spout member, including the assembly of the facing and hacking portions of the bimetallic billet, the rolling of such billet, the formation of the slug, thedie-termins operatin to produce the spout blank and the threading, are preferably performed cold. i

Referring now more particularly to Figures 7, 8 and 9, there is provided a container body member, designated generally by reference, nu-

s having a bottom 20 and a top 2| seamed thereto. The top 2l has an upwardly extendng hollow projection or neck 22 having an annular z a rounded sponds to the 'term "body member" as used in the claims), is preferably, although not necessarily, of tin-plate, that is to say, ferrous sheet metal coated with tin and manufactured in the usual way. Tin-plate is ordinarily produced by dipping 'a ferrous metal sheet into'a bath of molten tinso that usually the sheet is coated with tin on both sides. However, in the preferred construction 'shown inthe drawings it is meral s, which may comprise a side wall portion sumcient if the outside only of the top, or, for

that matter, the neck 22 alone or, indeed, only the outer surfaceof the neck, be co'ated. with tin.

- When a sheet of ferrous metal is coated with tin a'n iron-tin alloy is formed, the coating ordinarly containing at least 4 per cent; of such alloy. This percentage ranges up to in the neighborhood of 17 /2 per cent. or over, depending upon the materials used' and the process of manu- In Figure 9 the top. 2| of thecan is` shown as comprising ferrous metal 25 having a tin coating 26 on bota sides. No attempt is made to sho'w the ti cating in Figures 'I and- 8 due to their relatively smalf scale. ,Furthern'ora the relative thicknesses of the ferrous material "and the tin coating in 9 are not in tended to be accurate, thisigure being purely diagrammatic and for the purpose of illustrating the invention as well as possible. 1'

The body andspout members as above described are assembled by introduction of the neck 22 'of the body member within the skirt 21 of the spout member', after first applying a suitable flux either to the interier of the skirt or tothe exterior of the neck, the parts preferably being so proportioned that the inwardly directed portion of the spout member above the skirt will rest snugly upon the rim 24 of the neck. The diameter oi' the skirt is such that it snugly flts. over the neck. Thusthe solder is preferably in intimate contact both with the interior of the skirt otthe spout member and with the exterior of the neck oi' the body member. When the ,parts are thus 'assembled heat is preferably applied to the assembled structure, this conveniently being done by bringing heated electrodes or dies into contact with the outer surface of the skirt 21. In Figure 8 there are shown heated crimping dies 28 which simultaneously apply heat and crimping pressure to crimp the skirt about the neck of the body member and with a portion lying within and against the portion 23 of the neck. The dies I may be of any suitable form, the showing of- Figure 8 being purely diagrammatic;

Whether or not the skirt of the spout member is crimped about the neck of the body member, pressure between the skirt and neck is preferably applied, which, if there is to be no crimping, may be done by pressure applying members similar to the dies 28 but without the projections for forcing the portion of the skirt within the portion 23 of the neck. In fact, it is possible to do away entirely with the portion 23 of the neck and to simply press the skirt and neck firmly together while applying heat. Alternatively, the skirt and neck may be deformed or crimped together 'either before or after the application of heat instead of simultaneously therewith. i

The application of heat raises the temperature of the assembled structure to a point above the melting point of the solder but below the melting points of the materials of which the body and spout members are made. The entire assembled structure is, however, heated sumciently that a portion of the body member and a portion of the spout member enter into a solid Chemical solution with the solder whereby to form a strong and permanent bond between the respective members. The bond is made up of the solder having adjacent one side a solid Chemical solution between the solder and the plastic metal and having adjacent the other side a solid chemical solution between the solder and the iron-tin alloy in the tin coating onthe body member;

No' limitation is intended to be imposed by the above description of the theory of action as at present understood. The method described may also be used to advantage in attaching spout members to container body members when the parts are made of materials other than those specifically referred to herein. The method above described of forming a container member with a lining or layer of solder suitably positioned for cooperation with another member upon assembly to join the members together enables th'nani facture in an exceptionally simple, easy and economical manner of an improved product.

It is to be understood that thecan' or body member is filled with oil before thespout member is applied and that the usual screw cap is applied,"

to the outlet of the spout member. While I have shown and described a pre'sent preferred embodiment of the invgptio'n and a present preferred method of practicing the same, it is to be distinctly understood that the invention is not limited thereto but'may be otherwise Variously embodied and practiced within the scope of the following claims.

I claim: v

1. A method of making composite' metallic structures, comprising forming a bimetallic billet comprising a metal hacking and a faclng of solder, rolling said billet. into sheet-like form, blanking therefrom a bimetallic blank of pre determined size and shape, shapng said bimetallc blank to form a part adapted for incorporation in a. composite metallic structure with the solder disposed at a predetermined position thereon, assembling said part with another part with the solderin contact with said other part,

and melting and then hardening the solder to bond said parts together.

2. A method of making spouted containers, comprising providing a container body member, cold forming a spout member having a portion adapted to interfit with a portion of 'the body member and with a layer of solder on said portion of the spout member, interfitting said body 'and spout members with said layer of solder opposite said portion of the body member, and melting and then hardening the solder to bond said members together.

3. A method of making spouted containers, comprising providing a container body member, providing a metal blank .having solder thereon, deforming said blank to form a spout member adapted to interfit With said container body member, interfitting said body and spout members with at least portion of the solder opposite a portion of the body member, and melting and then hardening the solder to bond said members together.

4. A method of making spouted containers, comprising providing a container body member having a projection, providing a metal blank having solder thereon, die-forming said blank 'to form a spout member having a portion adapted to receive the projection of the body member and with at least a portion of the solder disposed at the inner surface of said portion .of the spout member, inserting 'said projection of the body into said portion of the spout member, and melting and then hardening the solder to bond said members together.

5. A method of making spouted containers, comprising providing a container body member of tin coated ferrous material, providing a plastic metal blank having solder thereon, deforming said blank to form a spout member adapted to intert with said container body member, interftting said body and spout members with at least a portion of the solder opposite a portion of the body member, and melting and then hardening the solder to bond said members to gether.

of the solder disposed at the inner surface 'f said skirt portion of the spout member, ins'erting said projection of the body member into said skirt portion of the spout member with the solder' opposite the tin coating of said projection, and melting and then hardening the solder to bond said members together. v

7. A method of making a solder-lined plastic metal spout adapted to be soldered over'a. container neck; comprising forming a plastic metal blank having solder applied thereto and dieforming said blank into said spout and in such manner as to dispose the solder at at least a portion of the interier of said spout to enable soldering the same to the container neck simply by positioning the spout thereover and 'application of heat.

- ROLAND M. KENAH. 

